99 TJ Blower Motor Fan Issue

[Rick Bo]

Hi Folks,

Some years ago, I had melted switches, connectors and wires. I patched everything up and got a new knock off Auto Zone blower motor and also, I installed relays in the 3rd and the 4th speed (direct current) circuits that lead to the resistor to relieve the high current that runs through the switches. It ran fine for years and now the new relays have melted. First question, should I fix this and go with the additional aftermarket relays or should I just rebuild everything back to original with Mopar/Crown parts? Would it help to put a lower amp fuse in to protect the switches and wires? Second question, there is a thick bright green wire on the connector that plugs into the 4 speed dial on the left side of the panel. I cant remember where it goes. Also the switch on the right side that selects vent-A/C-heat-Defrost, used to have a 3 lead connector on it. There are replacement connectors, but I cant remember which wires go to it. One more thing, I found this replacement harness for the resistor side of the wiring, but it has an extra connector, (top right with yellow and red wires) does anyone know what that is?

 

[Chris]

I'm confused... Why did you add relays to it? Why not just leave everything the way it came from the factory (or return it to that way at least), as that should be trouble free for decades.

Just put it back to stock. This is one of those cases where if it ain't broke, don't fix it. Not trying to be rude at all (please don't take it that way). I'm simply saying that it doesn't have to be this complicated.

 

[Rick Bo]

Chris, What happened, was that it had quit working. I'm guessing that the original blower motor went bad and melted wires, connectors and 2 switches. There are articles about cutting the wires and putting in relays to lower the amount of heat that goes through the system. I tried it and did work for years, but failed. At this point, I would like to put everything back to original. The wiring diagrams in the manual are difficult to follow. I'm looking for info to patch it back together like original.
Thank you for responding, Rick